Method of making solar array with aluminum foil matrix

Abstract

The disclosure relates to a method of making solar cell arrays and modules and the arrays and modules wherein the arrays are formed of semiconductor spheres of P-type interior having an N-type skin housed in a pair of aluminum foil members which form the contacts to the P-type and N-type regions. The foils are electrically insulated from each other and are flexible. Multiple arrays can be interconnected to form a module of solar cell elements for converting light energy into electrical energy.

What is claimed: 
     
       1. A method of forming a solar array comprising the steps of: (a) providing a first aluminum foil,   (b) forming apertures of a first diameter in said foil at predetermined locations thereon,   (c) providing a spheroid shaped semiconductor particle having a first conductively skin over a second conductivity type opposite said first type center in each of said apertures, each of said particles having a second diameter slightly larger than said first diameter, whereby said particles protrude from both sides of said foil,   
     
     
       (d) bonding said foil to said first conductivity type regions in said apertures, 
     
     
       (e) removing the first conductivity type skin on one side of said first foil, 
     
     
       (f) forming an insulating layer on the said one side of said first foil and on the surface of said particles, from which the first conductivity type layer was removed, 
     
     
       (g) removing a portion of the second conductivity type centers of said particles and the insulating layer thereover, and 
     
     
       (h) bonding a second aluminum foil to the regions from which said portions of the second conductivity type centers were removed. 
     
     
       2. A method as set forth in claim 1 further including the step of roughening the regions from which a portion of the second conductivity type centers were removed prior to step (h). 
     
     
       3. A method as set forth in claim 2 further including the step of forming an antireflective coating over the surface of said first foil remote from said second foil. 
     
     
       4. A method as set forth in claim 3 wherein step (d) includes disposing said particles in said apertures with the equators of said particles forward of the surface of said first foil remote from said second foil. 
     
     
       5. A method as set forth in claim 2 wherein step (d) includes disposing said particles in said apertures with the equators of said particles forward of the surface of said first foil remote from said second foil. 
     
     
       6. A method as set forth in claim 1 further including the step of forming an antireflective coating over the surface of said first foil remote from said second foil. 
     
     
       7. A method as set forth in claim 6 wherein step (d) includes disposing said particles in said apertures with the equators of said particles forward of the surface of said first foil remote from said second foil. 
     
     
       8. A method as set forth in claim 1 wherein step (d) includes disposing said particles in said apertures with the equators of said particles forward of the surface of said first foil remote from said second foil. 
     
     
       9. A method as set forth in claim 1 wherein said first conductivity type is N-type and said second conductivity type is P-type.